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mrfartsalot

2001 suzuki quadmaster 500 4x4 rev limiter when in any gear other than neutral

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I have a 2001 suzuki quadmaster 500 4x4 that has a rev limiter when it is in any gear other than neutral, i have already fixed a bunch of stuff on it and would love to just bypass it if anyone knows how. Thanks for any help.

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Sounds more like the jets are stopped up. Have you been through the carb yet? There may be enough fuel to rev unloaded but cant supply enough fuel under load due to blockage. 

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@MarkinAR i have been in the carb but wasn't able to clean it as good as i wanted to due to the previous owner stripping pretty much everything in it.

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Even more reason to not start bypassing rev limiters just yet. There are very good rebuild kits for the carbs that have everything inside the package.  Start there and get familiar with the carb, jet size and air/fuel setting. 
Unless the carburetor body has a stripped part ?

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Update: The issue is a wiring issue with the signal wire for the reverse limiter getting power from somewhere other than the neutral switch. My temporary fix is to cut the wire and it is running great.

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That's interesting.  I guess somehow the reverse gear rev limiter is interfering with forward gears as well.  Some of them have a reverse limiter lockout on the handlebar, so i wonder if grounding or breaking ground would just disable the reverse rev limiter completely....

Neat find!

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I hope this is good info. A buddy of mine thinks he got a bad buy on a quad master. He's not close to where I live or I would go help him plus he's more then able to fix shit. He's been through everything on the bike so this will be the only thing left !

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1 hour ago, Frank Angerano said:

@mrfartsalot i have someone that has the same quad and is having the same issue. So it would be a huge help if this works.  
I cant see that video. @Ajmboy can you help me out converting that video ?  

That's because its an mp4 file and I think you are on an ipad, right? I converted it to a .MOV

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Im on the iPad when I'm home, phone when im out and about.  I need to set up the ipqd like you said a desk top view?

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Just now, Frank Angerano said:

Im on the iPad when I'm home, phone when im out and about.  I need to set up the ipqd like you said a desk top view?

I'm not sure if you'll be able to see mp4 videos.  What happens is that when people upload videos from an apple device, it's .MOV file but other devices are .MP4. Apple doesn't play .MP4 natively from what I understand.

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@Frank Angerano there are a couple things to check before modifying the wiring from the research i did overcharging/ undercharging can cause issues that are similar and also the cdi can go bad and cause a similar issue, also check the valve adjustment. i will try to get better pictures of what i did but the neutral switch should be grounding the wire going to the cdi to tell it it is in neutral this also allows the starter to be activated. In my case the wiring on my quad is already hacked up so i had no problems cutting the wire and if it didn't work splicing it back together.

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No issues cutting and re splicing. All the above mentioned testing was done. I was going to put the cdi on the chopping block as well. But I would like to try a few more things before he spends the money on the cdi.  

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10 hours ago, Frank Angerano said:

@Ajmboy is there a set up for my iPad that will show different desktop then my phone?

If you are using Safari, should be same as iPhone I think, where when you hit the share button it brings up an option to request desktop site:

FA504C8B-AAEB-47E9-81EF-BED528D46513.jpeg.0407fd7878d0678cc44e60b54732200a.jpeg

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I have a 2000 quadmaster doing the same exact thing. I've replaced the CDI with a new OEM unit.  Replaced the stator and coil with aftermarket units.  I've run a new wire to the coil.  I've cut the blue/red wire.  I've cleaned the grounds. All to no avail.  I'm at my witts end. 

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